Durable and secured switch assembly

ABSTRACT

A durable and secured switch assembly includes an alternate action switch with a push button on one end and two primary cable terminals on the opposing end. The switch is secured in a housing with a lumen configured to securely retain the switch body. A first section of the lumen at the proximal end includes peripheral spacing for epoxy between the switch body and the inside wall of the housing. A second section of the lumen at the distal end includes a second peripheral spacing for epoxy between the switch body and the inside wall of the housing. The second section includes a peripheral notch for securing a cover that encloses the primary cable terminals in a cavity that is filled with epoxy. The housing includes a primary channel that connects a primary cable to the primary cable terminals and secondary channel for securing a secondary cable to the housing.

BACKGROUND OF THE INVENTION Field of the Invention

Embodiments of the invention relates to the field of electrical switchassemblies. More specifically, the invention relates to a durable andsecured housing for a switch in high vibration environments.

Description of the Related Art

Most military aircraft pilots carry their personal communicationequipment as part of their flight suit. Usually when a pilot enters thecockpit, he/she plugs the communication equipment cable into theappropriate aircraft's communication system port. Currently, thepersonal communication equipment cable includes a switch and housingassembly that is susceptible to unintentional activation by being bumpedin the narrow confines of the cockpit, is bulky and is hard to feel,especially for a person wearing a thick glove. The size of the prior artswitch is one of the reasons that it is difficult to utilize since oneneeds to locate the rocker in the middle of the large housing and thenactuate. The switch assembly is also susceptible to fracturing and tomoisture accumulation.

Accordingly, there is a need for a switch assembly for personalcommunication equipment that avoids the aforementioned problems in theprior art.

BRIEF SUMMARY OF THE INVENTION

One or more embodiments of the invention are directed to a durable andsecured switch assembly that is much more compact than prior art designsand may be simply actuated by finger or palm regardless its position.The invention comprises an alternate action switch enclosed in a tubularhousing. The switch comprises a switch body, a push button on a proximalend of the switch body, and two primary cable terminals on a distal endof the switch body.

In one or more embodiments, the housing has a lumen configured tosecurely retain the switch body. The lumen has first section that isconfigured to provide a first peripheral spacing between the switch bodyand the wall of the housing at the proximal end of the switch body. Thelumen also has a second section that is configured with a secondperipheral spacing between the switch body and the wall of the housingat the distal end of the switch body. Between the first and secondsection of the lumen is a section that acts as a stop to preventdownward movement of the switch body within the housing. The secondsection includes a peripheral notch near its bottom end. The housingfurther comprises a channel across its bottom end, i.e. from the leftside to the right side. The channel comprises a first portion of aprimary cable channel.

In one or more embodiments, a cover that is configured to snap fit intothe peripheral notch is coupled to the distal end of the housing toenclose the primary cable terminals. The cover includes a cavity for theprimary cable terminals. The cover includes the second portion of theprimary cable channel running from one side of the cover to an opposingside of the cover. The first and second portions together form anorifice that is a channel for connecting a primary cable to the primarycable terminals.

In one or more embodiments, the cover further comprises one or moreexternal access holes for injecting epoxy into the cavity.

In one or more embodiments, the first peripheral spacing, the secondperipheral spacing and the cavity are filled with epoxy or similar typenon-conductive material.

In one or more embodiments, the spacing between an outside wall of thehousing and an outside wall of the cover forms a secondary cable channelfor securing a secondary cable to the housing.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other aspects, features and advantages of the inventionwill be more apparent from the following more particular descriptionthereof, presented in conjunction with the following drawings wherein:

FIG. 1 is an illustration of a personal communication cable assemblywith switch enclosed in a housing in accordance with one or moreembodiments of the present invention.

FIG. 2A is a left/right side view of a personal communication cableswitch and the durable protective housing in accordance with one or moreembodiments of the present invention.

FIG. 2B is a front/back side view of the personal communication cableswitch and the durable protective housing in accordance with one or moreembodiments of the present invention.

FIG. 2C is a cross-sectional view of the personal communication cableswitch and the durable protective housing in accordance with one or moreembodiments of the present invention.

FIG. 3A is a top view of the durable protective housing in accordancewith one or more embodiments of the present invention.

FIG. 3B is a left/right side view of the durable protective housing inaccordance with one or more embodiments of the present invention.

FIG. 3C is a cross-sectional view (i.e. front to back) of the durableprotective housing in accordance with one or more embodiments of thepresent invention.

FIG. 3D is a cross-sectional view (i.e. left to right) of the durableprotective housing in accordance with one or more embodiments of thepresent invention.

FIG. 4A is a top view of the back fitting of the durable protectivehousing in accordance with one or more embodiments of the presentinvention.

FIG. 4B is a left/right side view of the back fitting for the durableprotective housing in accordance with one or more embodiments of thepresent invention.

FIG. 4C is a cross-sectional view (i.e. front to back) of the backfitting for the durable protective housing in accordance with one ormore embodiments of the present invention.

FIG. 4D is a cross-sectional view (i.e. left to right) of the backfitting for the durable protective housing in accordance with one ormore embodiments of the present invention.

FIG. 5A is an isometric view of the alternate action switch inaccordance with one or more embodiments of the present invention.

FIG. 5B is a left/right side view of the alternate action switch inaccordance with one or more embodiments of the present invention.

FIG. 5C is a top view of the alternate action switch in accordance withone or more embodiments of the present invention.

FIG. 5D is a bottom view of the alternate action switch in accordancewith one or more embodiments of the present invention.

DETAILED DESCRIPTION

The present invention comprising a durable and secured switch assemblywill now be described. In the following exemplary description numerousspecific details are set forth in order to provide a more thoroughunderstanding of embodiments of the invention. It will be apparent,however, to an artisan of ordinary skill that the present invention maybe practiced without incorporating all aspects of the specific detailsdescribed herein. Furthermore, although steps or processes are set forthin an exemplary order to provide an understanding of one or more systemsand methods, the exemplary order is not meant to be limiting. One ofordinary skill in the art would recognize that the steps or processesmay be performed in a different order, and that one or more steps orprocesses may be performed simultaneously or in multiple process flowswithout departing from the spirit or the scope of the invention. Inother instances, specific features, quantities, or measurements wellknown to those of ordinary skill in the art have not been described indetail so as not to obscure the invention. It should be noted thatalthough examples of the invention are set forth herein, the claims, andthe full scope of any equivalents, are what define the metes and boundsof the invention.

For a better understanding of the disclosed embodiment, its operatingadvantages, and the specified object attained by its uses, referenceshould be made to the accompanying drawings and descriptive matter inwhich there are illustrated exemplary disclosed embodiments. Thedisclosed embodiments are not intended to be limited to the specificforms set forth herein. It is understood that various omissions andsubstitutions of equivalents are contemplated as circumstances maysuggest or render expedient, but these are intended to cover theapplication or implementation.

The term “first”, “second” and the like, herein do not denote any order,quantity or importance, but rather are used to distinguish one elementfrom another, and the terms “a” and “an” herein do not denote alimitation of quantity, but rather denote the presence of at least oneof the referenced item.

One or more embodiments of the present invention will now be describedwith references to FIGS. 1-5D.

One or more embodiments of the invention comprises a switch and housingassembly 200 in a personal communication cable assembly 100. Thepersonal communication cable includes one or more connectors, e.g. 116,112, and 102. The personal communication cable further includes aprimary cable 106 electrically connected a switch 200 and a secondarycable 108 mechanically retained by the switch housing. On each side ofthe switch is an adhesive heat shrink 110.

FIGS. 2A-2C are illustrations of the durable protective housing andswitch assembly 200 in accordance with one or more embodiments of thepresent invention. As illustrated, the switch assembly 200 comprisesalternate action (i.e. Push On-Push Off) switch 500; housing 300; backfitting (or cover) 400; primary cable channel 210; and secondary cablechannel 212. In one or more embodiments, the alternate action switch 500is configured to fit inside lumen 310 of the housing unit 300. The spacein the lumen 310 of housing 300 that is not occupied by the switch, e.g.222 and 224, is filled with epoxy. In addition, the space inside backfitting, e.g. 226, is filled with epoxy.

FIGS. 3A-3D are illustrations of the housing 300 in accordance with oneor more embodiments of the present invention. As illustrated, thehousing 300 comprises a tubular body structure with a lumen 310 runningthe length of the body, i.e. from the top (or proximal) end to thebottom (or distal) end. Housing 300 further comprises a channel, e.g.304, across its bottom end, i.e. from the left side to the right side.Channel 304 is a first portion of the primary cable channel 210.

In one or more embodiments, the perimeter of housing 300 comprises afirst outside section 301 that begins from the top of the housing andruns towards the bottom of the housing; a second outside section 302abutting the first section 301 and that is larger than the first section301; and a third outside section 303 abutting the second section 302 andthat is approximately the same size as the first outside section 301 andruns to the bottom of the housing 300. The space, e.g. 306, defined bysidewall of the third outside section 303 and bottom wall of the secondoutside section 302 comprises a first portion 306 of the secondary cablechannel 212 around the perimeter of the bottom end of the housing 300.The peripheral shape of body 300 may be cylindrical, cubic, or any othershape. Those of skill in the arts would appreciate that the externalshape of body 300 may differ from that shown without deviating from theinvention.

Lumen 310 comprises a first section 311 at the proximal end with adiameter slightly larger than the largest outer diameter, i.e. 513, ofswitch 500. The lumen 310 of housing 300 further comprises a secondsection 313, abutting the first section 311, with a diameter smallerthan section 311 and approximately equal to the largest outer diameter,i.e. 513, of switch 500 thus sufficient to snugly fit section 513 ofswitch 500. The depth of section 313 of the lumen is approximately theheight of section 513 of switch 500. In one or more embodiments, thediameter of section 311 is sufficient to provide space, e.g. 222,between the outside section 511 of switch 500 and the inside wall ofsection 311 for epoxy or similar material for sealing the space aroundthe switch body at section 511. The epoxy seal helps prevent moisturefrom entering the switch assembly 200. Those of skill in the art wouldappreciate that materials other than epoxy may be used for sealing inspace 222. In one or more embodiments, space 222 may be omittedentirely.

The lumen 310 of housing 300 further comprises a third section 315abutting the second section 313 and running to approximately halfwaytowards the distal end of housing 300. The diameter of the third section315 is smaller than the first section, i.e. 311, and second section,i.e. 313, and is sufficient to act as a stop to restrain the downwardmovement of switch 500. The lumen 310 of housing 300 further comprises afourth section 317 abutting the third section 315 and running to thedistal end of housing 300. The diameter of the fourth section 317 islarger than the third section, i.e. 315, and provides space for epoxy toseal the space around the switch body at section 515. The epoxy sealhelps prevent moisture from entering the switch assembly 200. Those ofskill in the art would appreciate that materials other than epoxy may beused for sealing in space 224. In one or more embodiments, space 224 maybe omitted entirely.

The fourth section 317 of lumen 310 further comprises a notch 312 aroundthe inside perimeter of lumen 310 near the distal end of housing 300.Notch 312 is configured to receive and flange 409 of bottom fitting (orcover) 400 thus securing the cover 400 to the housing 300.

FIGS. 4A-4D are illustrations of the cover 400 in accordance with one ormore embodiments of the present invention. As illustrated, the cover 400comprises a bottom wall 402 from which a sidewall extends upwardlytherefrom to form a recessed compartment (or cavity) 420. The sidewallof the cover 400 comprises a first section 403 rising from the bottomwall 402 and adjoining a smaller second section 404. The perimeter offirst section 403 is approximately the same as the perimeter of section302 of housing 300 and the perimeter of second section 404 isapproximately the same as the perimeter of section 303 of housing 300.Thus, space, e.g. 406, defined by the top wall of the first section 403and the sidewall of second section 404 comprises a second portion of thesecondary cable channel 212 around the perimeter of device 200. Thesidewall of the cover 400 further comprises a third section 405 abuttingthe second section 404. The perimeter of section 405 is configured totightly and completely fit into the fourth section 317 of lumen 310 ofhousing 300. The fourth section 407 comprises a tip with an outwardlyextending flange 409, which is configured to snap fit into notch 312 inthe housing unit 300.

Cover 400 further comprises a second channel, e.g. 410, across its topside. Channel 410 is a second portion of the primary cable channel 210.The depth of channel 410 runs from the tip of the cover section 405 thetop of first section 403.

Cover 400 further comprises one or more holes, e.g. 421 and 422, at thebottom wall to provide access to cavity 420 from the outside. Holes 421and 422 are used to fill compartment 420 with epoxy after cover 400 issnap coupled with housing 300.

FIG. 5A-5D are illustrations of alternate action switch 500. Asillustrated, switch 500 comprises push button 502 and terminals 506 and508 for connecting separate ends of the primary cable. Thus, terminals506 and 508 are approximately located in the primary cable channel whenswitch 500 is in the housing 300. In use, the user pushes button 502 toactivate or deactivate the switch.

As shown in the illustrations and discussed herein, the switch assemblyis compact in size, secure and stable with enhanced sealing to preventmoisture contamination. The switch assembly is also not susceptible toinadvertent activation. A user, e.g. pilot, wearing a thick glove caneasily activate the switch by finger or palm. The switch assembly alsoprovides tactile feedback to the user with the clicking action of thepush button 502.

While the invention herein disclosed has been described by means ofspecific embodiments and applications thereof, numerous modificationsand variations could be made thereto by those skilled in the art withoutdeparting from the scope of the invention set forth in the claims.

What is claimed is:
 1. A durable and secured switch apparatuscomprising: an alternate action switch comprising a switch body, a pushbutton on a proximal end of the switch body, and two primary cableterminals on a distal end of the switch body, wherein the two primarycable terminals are configured for in-line coupling of separate ends ofa primary cable; a housing having a lumen configured to securely retainthe switch body, wherein said lumen is further configured with a firstperipheral spacing between said switch body and a first section of saidlumen at the proximal end of said switch body, and a second peripheralspacing between said switch body and a second section of said lumen atthe distal end of said switch body, wherein said lumen further includesa stop between said first section and said second section to preventdownward movement of the switch body within said housing and aperipheral notch in said second section, wherein the two primary cableterminals are perpendicular with respect to the peripheral notch and theprimary cable channel, wherein said housing further includes a firstpart of a primary cable channel running across and centered at saiddistal end of said housing, wherein at least a top surface of the pushbutton is located external to the housing; and a cover configured tosnap fit into said peripheral notch to secure said cover to said housingand enclose said primary cable terminals, wherein said cover includes acavity for said primary cable terminals, wherein said cover furtherincludes a second part of said primary cable channel running from oneside of said cover to an opposing side of said cover, wherein said firstpart and said second together form said primary cable channel configuredfor electrically in-line coupling of the primary cable terminals withthe primary cable.
 2. The apparatus of claim 1, wherein said coverfurther comprises one or more external access holes for injecting asealing material into said cavity.
 3. The apparatus of claim 1, whereinsaid first peripheral spacing, said second peripheral spacing and saidcavity are filled with a sealing material.
 4. The apparatus of claim 1,wherein a spacing between an outside wall of said housing and an outsidewall of said cover forms a secondary cable channel that is parallel tothe primary cable channel.
 5. The apparatus of claim 4, wherein saidsecondary cable channel is configured for mechanically retaining but notelectrically coupling a secondary cable to said housing.
 6. Theapparatus of claim 1, wherein the cover has at least one diameter equalto a diameter of the distal end of the housing.
 7. The apparatus ofclaim 1, wherein the cover has at least one diameter equal to a diameterof the distal end of the housing and the at least one diameter is wherethe cover snap fits into the housing.
 8. The apparatus of claim 1,wherein the cover has more than one section of different diameters. 9.The apparatus of claim 1, wherein the cover has more than one section ofdifferent diameters, wherein at least one diameter of the more than oneis equal to a diameter of the distal end of the housing and the at leastone diameter is where the cover snap fits into the housing.
 10. Theapparatus of claim 1, wherein the first section of said lumen comprisestwo sections of different diameters.
 11. The apparatus of claim 10,wherein the stop has a smallest diameter of all sections of the lumen.12. The apparatus of claim 1, wherein the stop has a smallest diameterof all sections of the lumen.
 13. A system comprising: an alternateaction switch comprising a switch body, a push button on a proximal endof the switch body, and two primary cable terminals on a distal end ofthe switch body, wherein the two primary cable terminals are in-linecoupled to separate ends of a primary cable; a housing having a lumenthat securely retains the switch body, wherein said lumen has a firstperipheral spacing between said switch body and a first section of saidlumen at the proximal end of said switch body, and a second peripheralspacing between said switch body and a second section of said lumen atthe distal end of said switch body, wherein said lumen further includesa stop between said first section and said second section to preventdownward movement of the switch body within said housing and aperipheral notch in said second section, wherein the two primary cableterminals are perpendicular with respect to the peripheral notch and theprimary cable channel, wherein said housing further includes a firstpart of a primary cable channel running across and centered at saiddistal end of said housing, wherein at least a top surface of the pushbutton is located external to the housing; a cover that is snap fit intosaid peripheral notch that secures said cover to said housing andencloses said primary cable terminals, wherein said cover has a cavityfor said primary cable terminals, wherein said cover further includes asecond part of said primary cable channel running from one side of saidcover to an opposing side of said cover, wherein said first part andsaid second together form said primary cable channel; and the primarycable is within said primary cable channel.